US8747170B2 - Connector assemblies and systems and methods for forming disconnectable joint assemblies - Google Patents

Abstract

A disconnectable joint system includes first and second connectors and a coupling fastener. The first connector defines a first conductor bore to receive a first cable conductor, and a first coupling portion including a first coupling bore and a first integral interlock feature. The second connector defines a second conductor bore to receive a second cable conductor, and a second coupling portion including a second coupling bore and a second integral interlock feature. The first and second coupling portions are mateable in an interlocked position wherein the first and second interlock features are interlocked with one another, the first and second coupling bores are substantially aligned, and the coupling fastener can be inserted through the first and second coupling bores and tightened to securely couple the first and second connectors to one another. The first and second connectors can be separated upon removal of the coupling fastener.

Description

RELATED APPLICATION(S)

The present invention claims the benefit of and priority from U.S. Provisional Patent Application No. 61/641,574, filed May 2, 2012, the disclosure of which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to electrical cables and connections and, more particularly, to connector assemblies for disconnectable joints.

BACKGROUND OF THE INVENTION

Disconnectable joint assemblies are commonly used in electrical power transmission networks in urban environments. Electrical power cables to be spliced are each provided with a cable termination lug or connector. Each cable termination lug is disconnectably and reconnectably secured to the other by a bolt, for example.

Disconnectable joint assemblies as described above are useful in urban network applications where a utility may need the ability to disconnect a joint to sectionalize a piece of cable for repair, for example. By way of example, a bad or damaged cable may be disconnected from the joint assembly to remove the cable from the circuit in a quick and efficient manner, and then reconnected to the joint assembly after the repair is made.

In order to protect the joint, cable, and cable terminal lugs from the environment (e.g., moisture) and to protect technicians from the electrically energized components, joint sleeve systems are employed.

SUMMARY OF THE INVENTION

According to embodiments of the present invention, a disconnectable joint system for disconnectably electrically and mechanically connecting first and second electrical each including a respective electrical conductor includes a first connector, a second connector, and a coupling fastener. The first connector defines a first conductor bore and a first coupling portion. The first conductor bore is configured to receive the conductor of the first cable. The first coupling portion includes a first coupling bore defined therein, and a first integral interlock feature. The second connector defines a second conductor bore and a second coupling portion. The second conductor bore is configured to receive the conductor of the second cable. The second coupling portion includes a second coupling bore defined therein, and a second integral interlock feature. The first and second coupling portions are mateable in an interlocked position wherein the first and second interlock features are interlocked with one another and the first and second coupling bores are substantially aligned. When the first and second coupling portions are in the interlocked position, the coupling fastener can be inserted through the first and second coupling bores and tightened to securely couple the first and second connectors to one another. The first and second connectors can be separated upon removal of the coupling fastener.

According to embodiments of the present invention, a disconnectable joint assembly for disconnectably electrically and mechanically connecting first and second electrical cables each including a respective electrical conductor includes a first connector, a second connector, and a coupling fastener. The first connector defines a first conductor bore and a first coupling portion. The first conductor bore is configured to receive the conductor of the first cable. The first coupling portion includes a first coupling bore defined therein, and a first integral interlock feature. The second connector defines a second conductor bore and a second coupling portion. The second conductor bore is configured to receive the conductor of the second cable. The second coupling portion includes a second coupling bore defined therein, and a second integral interlock feature. The first and second coupling portions are mated in an interlocked position wherein the first and second interlock features are interlocked with one another and the first and second coupling bores are substantially aligned. The coupling fastener extends through the first and second coupling bores and securely couples the first and second connectors to one another. The first and second connectors can be separated upon removal of the coupling fastener.

According to method embodiments of the present invention, a method for disconnectably electrically and mechanically connecting first and second electrical cables each including a respective electrical conductor includes providing a disconnectable joint assembly including a first connector, a second connector, and a coupling fastener. The first connector defines a first conductor bore and a first coupling portion. The first conductor bore is configured to receive the conductor of the first cable. The first coupling portion includes a first coupling bore defined therein, and a first integral interlock feature. The second connector defines a second conductor bore and a second coupling portion. The second conductor bore is configured to receive the conductor of the second cable. The second coupling portion includes a second coupling bore defined therein, and a second integral interlock feature. The method further includes: mating the first and second coupling portions in an interlocked position wherein the first and second interlock features are interlocked with one another and the first and second coupling bores are substantially aligned; and with the first and second coupling portions in the interlocked position, inserting the coupling fastener through the first and second coupling bores and tightening the coupling fastener to securely couple the first and second connectors to one another.

Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments that follow, such description being merely illustrative of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are exploded, perspective views of a disconnectable joint system according to embodiments of the present invention.

FIG. 3 is a perspective view of a disconnectable joint assembly according to embodiments of the present invention and assembled using the joint system ofFIG. 1.

FIG. 4 is a cross-sectional view of the joint assembly ofFIG. 3 taken along the lines4-4 ofFIG. 3.

FIG. 5 is a perspective view of a first connector forming a part of the joint assembly ofFIG. 3.

FIG. 6 is a perspective view of a second connector forming a part of the joint assembly ofFIG. 3.

FIG. 7 is a perspective view of an exemplary electrical cable for use with the joint assembly ofFIG. 3.

FIG. 8 is a cross-sectional view of a covered connection including the joint assembly ofFIG. 3.

FIG. 9 is a cross-sectional view of a covered connection including a disconnectable joint assembly according to further embodiments of the present invention.

FIG. 10 is a perspective view of an alternative coupling bolt for use in the joint assembly ofFIG. 3.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.

Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90° or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

As used herein, “monolithic” means an object that is a single, unitary piece formed or composed of a material without joints or seams.

As used herein, “cold-applied” or “cold-applied cover” means that the cover or component can be assembled or installed about a substrate (e.g., a cable) without requiring the use of applied heat at the time of installation.

As used herein, “cold shrink” or “cold shrink cover” means that the cover or component can be shrunk or contracted about a substrate (e.g., a cable) without requiring the use of applied heat.

With reference toFIGS. 1-8, a disconnectablejoint system105 according to some embodiments of the present invention is shown therein. Thesystem105 can be used to construct a disconnectable joint assembly100 (hereinafter, “thejoint assembly100”) according to some embodiments of the present invention. Thejoint assembly100 can be used to form a mechanical and electrical connection or joint10 between twopower cables40,50, for example. In some embodiments, theconnection10 is provided with a cover or coverassembly170 to form an environmentally protected connection.

Thesystem105 includes afirst connector110, asecond connector130, and acoupling fastener150. According to some embodiments and as shown, thecoupling fastener150 is a threaded fastener and, in some embodiments, is a bolt. Theconnectors110,130 incorporate an integral alignment andinterlock system102 as discussed below. Theconnectors110,130 are adapted and configured to provide mechanical and electrical connections between eachconnector110,130 and arespective cable40,50 and between each other, as discussed hereinbelow.

According to some embodiments and as illustrated, the first connector110 (FIG. 5) is a shear bolt connector including an electrically conductive (e.g., metal)connector body112 and one or more (as shown, two) clamp threaded fasteners orbolts118. Theconnector body112 has axially opposed ends112A and112B defining a connector axis A-A. Theconnector body112 includes a cable ormain portion114 and a coupling portion, tab, arm or lug120 extending to theend112B, A conductor bore116A is defined in themain portion114, communicates with acable receiving opening116B on theend112A, and extends generally coaxially with the axis A-A. Threaded bolt bores116C extend radially through themain portion114 and intersect the conductor bore116A. The conductor bore116A is configured to receive a terminal segment of thecable conductor40. Themain portion114 has anend face114B and a generally cylindricalouter surface114A.

Eachconductor clamp bolt118 includes ashank118A, ahead118B, and a shear region orsection118C. Thehead118B is configured to operatively engage a driver tool. Theshank118A has an external thread complementary to the thread of thebores116C. Theheads118B on thebolts118 are configured to shear off of a remainder of the associated bolt118 (i.e., the threaded shank) at theregion118C when subjected to a prescribed torque.

Thecoupling lug120 extends axially from the lower part of themain portion114 from theend face114B. Thecoupling lug120 has a planarinner face122A, anend face122B, and a semi-cylindricalouter surface122C. A threadedcoupling bore124 extends radially through thecoupling lug120 from theinner face122A to theouter surface122C.

The coupling lug122 has alignment and interlock features defined therein in the form of two, side-by-side interlock slots126 extending into theinner face122A and defining apartition wall127 therebetween. Theinterlock slots126 extend transversely to the connector axis A-A. Theinterlock slots126 may be formed by machining, molding, or casting, for example.

The second connector130 (FIG. 6) includes aconnector body132 and clamp bolts118 (mounted in threadedbores136C) corresponding to and constructed in the same manner as theconnector body112 and theclamp bolts118. Thesecond connector130 has a connector axis B-B and aconductor bore136A generally coaxial therewith. Thesecond connector130 further includes a coupling portion, tab, arm, or lug140 extending axially from the upper part of themain portion134 and beyond theend face134B. Thecoupling lug140 has a planarinner face142A, anend face142B, and a semi-cylindricalouter surface142C. A nonthreaded coupling bore144 extends radially through thecoupling lug140 from theinner face142A to theouter surface142C.

Thecoupling lug140 has alignment and interlock features defined therein in the form of two, side-by-side interlock projections, tabs orposts146 extending radially inwardly from theinner face142A and defining agap slot147 therebetween. The interlock posts146 extend transversely to the connector axis B-B. The interlock posts146 may be formed by machining, molding, or casting, for example.

Thecoupling bolt150 includes ashank152, anupper head154, alower head156 joined to thehead154 by aneck154A, and a shear region orsection154B proximate the interface joint between theneck154A and thelower head156. Thehead154 is configured to operatively engage a driver tool. Theshank152 has an external thread complementary to the thread of thecoupling bore124. Thehead154 andneck154A are configured to shear off of a remainder of the bolt150 (i.e., thehead156 and the threaded shank152) at theshear section154B when thehead154 is subjected to a prescribed torque. Thecoupling bolt150 may be formed by machining, molding, or casting, for example.

According to some embodiments, theconnector bodies112,132 are formed of steel, copper, brass or aluminum. According to some embodiments, the clamp bolts are118 are formed of copper, brass or aluminum. According to some embodiments, thecoupling bolt150 is formed of copper, brass or aluminum.

As shown inFIG. 7, thecable40 includes a primaryelectrical conductor42, apolymeric insulation layer44, asemiconductor layer45, one or moreneutral conductors46, and ajacket48, with each component being concentrically surrounded by the next. According to some embodiments and as shown, theneutral conductors46 are individual wires, which may be helically wound about thesemiconductor layer45; however, metal tape shielding or the like may be used instead. Theprimary conductor42 may be formed of any suitable electrically conductive materials such as copper (solid or stranded). Thepolymeric insulation layer44 may be formed of any suitable electrically insulative material such as crosslinked polyethylene (XLPE) or ethylene propylene rubber (EPR). Thesemiconductor layer45 may be formed of any suitable semiconductor material such as carbon black with polyethylene. Theneutral conductors46 may be formed of any suitable material such as copper. Thejacket48 may be formed of any suitable material such as EPDM. The cable50 (FIG. 8) is similarly constructed with a primaryelectrical conductor52, apolymeric insulation layer54, asemiconductor layer55, one or moreneutral conductors56, and ajacket58 corresponding tocomponents42,44,45,46 and48, respectively. According to some embodiments, thecables40,50 are low-voltage or medium-voltage (e.g., between about 5 and 46 kV) power transmission cables. Thecables40,50 are exemplary and it will be appreciated that connector assemblies as disclosed herein can be used with other types of cables.

The disconnectablejoint system105 can be used and installed on thecables40,50 as follows to form the joint10.

Thecables40,50 are prepared as shown inFIG. 7 such that a terminal segment of each cable layer extends beyond the next overlying layer.

The end of thecable conductor42 is inserted through the opening116B into the conductor bore116A. Theshear bolts118 of theconnector110 are rotated and torqued using a suitable driver (e.g., an electrically insulated powered or non-powered driver including a drive socket N to operatively receive and engage the heads of thebolts118,150) until theheads118B thereof shear or break off of theshanks118A at a prescribed load. Theconductor42 is thereby electrically connected to theconnector110 and mechanically clamped in thebore116A, and the remaining portions of thebolts118 are flush or approximately flush with theouter surface114A of theconnector110. Thecable conductor52 is likewise inserted through theopening136B and secured in the conductor bore136A of theconnector130 using theshear bolts118.

Theconnectors110 and130 are then preliminarily mated or joined in an interlocked position. More particularly, theconnectors110,130 are relatively positioned such that the interlock posts146 and the interlock slots126 (which collectively form the alignment and interlock system102) are generally laterally aligned with one another (i.e., are generally positioned at the same location along a joint lengthwise axis C-C (FIG. 4). Theconnectors110,130 are then relatively moved laterally together in a lateral mating or insertion direction I (FIG. 2) along a first lateral axis J-J (FIG. 2) so that theposts146 are received in theslots126, thepartition wall127 is received in thegap slot147, and the inner faces122A,142A are in abutment or close proximity. In this position, the couplinglug end face142B is in abutment with or close proximity to the main portion end face114B, theend face122B is in abutment with or close proximity to the mainportion end face134B, and the axis D-D of the coupling bore124 is substantially aligned with the axis E-E of the coupling bore144 as shown inFIG. 4.

Even in the absence of thecoupling bolt150, the interlock between theposts146 and theslots126 serves to retain theconnectors110,130 in their relative positions along the joint axis C-C. As long as the coupling lugs120,140 are prevented (e.g., by the installer's hand) from laterally separating along the axis J-J to an extent sufficient to remove theposts146 from theslots126, the interlock between theposts146 and theslots126 will prevent theconnectors110,130 from being axially separated (e.g., by a divergent axial pull force or forces F_A(FIG. 8) applied to or by thecables40,50). The interlocking features126,146 can thereby provide temporary strain relief.

The interlock between thepartition wall127 and thegap slot147 prevents the coupling lugs120140 from being relatively displaced (e.g., translated) along a lateral or sideward axis K-K (FIG. 2). The planar, complementary shapes of the inner faces122A,142A as well as the cooperating geometries of thefeatures126,146 can resist or prevent the coupling lugs120,140 from being twisted or rotated about the joint axis C-C so long as the inner faces122A,142A are held in abutment. The positive interlocking engagement as described above can thus ensure that the axes D-D, E-E of the coupling bores124,144 are maintained in alignment to facilitate insertion of thecoupling bolt150.

With the coupling lugs120,140 mated and aligned as described above, thecoupling bolt150 is inserted through the coupling bore144 and threaded into thecoupling bore124. Thehead154 is engaged with a suitable driver N and rotated and torqued until thehead154 andneck154A shear or break off at theshear region154B upon application of a prescribed load. As thebolt150 is torqued, thelower head156 seats in the counterbore or head bore144A and bears against theshoulder144B to apply a clamping load to the coupling lugs120,140. The joint10 and thejoint assembly100 are thereby completed.

With reference toFIG. 8, it can be seen that, according to some embodiments, theshear bolts118,150 once installed are nearly or approximately flush with the outer surfaces or profile of theconnectors110,130. In this way, thejoint assembly100 can present a generally smooth, regular outer profile with no or relatively few sharp edges or transitions. Such a geometry may be particularly beneficial when thejoint assembly100 is further covered by a cold-shrink or heat-shrinkable cover, as discussed below.

According to some embodiments and as reflected in the illustrative embodiment, theouter surfaces122C,142C of the coupling lugs120,140 collectively form a substantially cylindrical outer surface or profile that smoothly transitions to the outer profiles of the adjacentmain portions114,134.

When desired, theconnectorized cables40,50 can be disconnected from one another, without removing theconnectors110,130 from thecables40,50, by removing thecoupling bolt150 and disconnecting theconnectors110,130. Thecoupling bolt150 may be removed by drilling and driving thebolt150 out using an “easy out” tool, for example. Thecables40,50 may be disconnected in this manner in order to test one or both of thecables40,50 or an assembly attached to one of thecables40,50.

Theconnectors110,130 can thereafter be reconnected in the same manner as described above using anew coupling bolt150 to re-form the joint10.

According to some embodiments, the height H1 (FIG. 6) of eachpost146 is in the range of from about 0.03 to 0.25 inch. According to some embodiments, the width W1 (FIG. 6) of eachpost146 is in the range of from about 0.125 to 0.5 inch. According to some embodiments, the width W2 (FIG. 5) of thepartition wall127 is in the range of from about 0.06 to 0.25 inch. According to some embodiments, the depth H2 (FIG. 5) of eachslot126 is between about 0.04 and 0.26 inch greater than the height H1 of the receivedpost146. According to some embodiments, the width W3 (FIG. 6) of thegap slot147 is between about 0.07 and 0.26 inch greater than the width W2 of thepartition wall127.

According to some embodiments, the planar inner faces122A,142A extend across the full diameter or width of theconnector body112,132.

According to some embodiments, the joint10 (including the joint assembly100) is covered by thecover assembly170 to electrically insulate and cover the joint10 as shown inFIG. 8. Thecover assembly170 may be provided as a pre-expanded unit including a holdout device on which thecover assembly170 or some components thereof are mounted in an expanded state or position. Thecover assembly170 may be deployed and mounted on the intended substrates in a retracted state or position as shown inFIG. 8. According to some embodiments, thecover assembly170 is a cold shrink cover, meaning that it can be shrunk or retracted about the substrate without requiring the use of applied heat.

Thecover assembly170 includes aFaraday cage layer172, stress cone layers173, an inner sleeve (or insulation body)174, a semiconductor layer175, a metalshield mesh layer177, and an outer sleeve (or re-jacket)178.Sealant179A (e.g., mastic) may be provided to seal theouter sleeve178.Clamps179B or the like may be provided to secure themesh layer177 andcable neutrals46,56.

Theinner sleeve174 is tubular and defines an axially extending conductor through passage that communicates with opposed end openings.

TheFaraday cage layer172 is illustrated as a generally tubular sleeve bonded to the inner surface of theinner sleeve174. TheFaraday cage layer172 may be formed of a suitable elastically conductive elastomer. In use, theFaraday cage layer172 may form a Faraday cage to provide an equal potential volume about theconnector assembly100 so that an electric field is cancelled in the surrounding air voids.

The stress cone layers173 are illustrated as generally tubular sleeves bonded to the inner surface of theinner sleeve174 at either end thereof. The stress cone layers173 may be formed of a suitable electrically conductive elastomer. In use, the stress cone layers173 may serve to redistribute the voltage along the surface of thecable insulation44,54 to reduce or prevent the degradation of theinsulation44,54 that might otherwise occur.

Thesemiconductor layer176 fully circumferentially surrounds theinner sleeve174. According to some embodiments, thesemiconductor layer176 is coextensive with theinner sleeve174.

Theshield mesh layer177 fully circumferentially surrounds theinner sleeve174. According to some embodiments, theshield mesh layer177 includes opposed end sections that extend beyond the ends of theinner sleeve174 but do not extend as far out as theouter sleeve178. Theshield mesh layer177 may be formed of braided or woven copper filaments, for example.

Theouter sleeve178 fully circumferentially surrounds theshield mesh layer177. Theouter sleeve178 is tubular and defines an axially extending conductor through passage that communicates with opposed end openings.

Thesemiconductor layer176 can be formed of any suitable electrically semiconductive material. According to some embodiments, thesemiconductor layer176 is formed of an elastically expandable material. According to some embodiments, thesemiconductor layer176 is formed of an elastomeric material. According to some embodiments, thesemiconductor layer176 is formed of carbon black and silicone. Other suitable materials may include carbon black and EPDM.

Theinner sleeve174 can be formed of any suitable material. According to some embodiments, theinner sleeve174 is formed of a dielectric or electrically insulative material. According to some embodiments, theinner sleeve174 is formed of an elastically expandable material. According to some embodiments, theinner sleeve174 is formed of an elastomeric material. According to some embodiments, theinner sleeve174 is formed of liquid silicone rubber (LSR). Other suitable materials may include EPDM or ethylene propylene rubber (EPR). According to some embodiments, theinner sleeve174 has a Modulus at 100 percent elongation (M100) in the range of from about 0.4 to 0.52 MPa.

According to some embodiments, the thickness of theinner sleeve174 is in the range from about 0.07 to 2 inches. According to some embodiments, the length of theinner sleeve174 is in the range from about 8 to 30 inches.

Theouter sleeve178 can be formed of any suitable material. According to some embodiments, theouter sleeve178 is formed of an electrically insulative material. According to some embodiments, theouter sleeve178 is formed of an elastically expandable material. According to some embodiments, theouter sleeve178 is formed of an elastomeric material. According to some embodiments, theouter sleeve178 is formed of ethylene propylene diene monomer (EPDM) rubber. Other suitable materials may include neoprene or other rubber. According to some embodiments, theouter sleeve178 has a Modulus at 100 percent elongation (M100) in the range of from about 0.6 to 1.1 MPa.

According to some embodiments, the thickness of theouter sleeve178 is in the range of from about 0.11 to 0.25 inch. According to some embodiments, the length of theouter sleeve178 is in the range of from about 15 to 35 inches.

While a multi-component cold-shrink, cold-applied cover assembly is described above and shown inFIG. 8, other types and configurations of covers and cover assemblies may be used. For example, a heat-shrinkable cover or cover assembly may be applied about thejoint assembly100. Thejoint assembly100 may be covered with more or fewer components (e.g., covered only by an insulating re jacket sleeve).

With reference toFIG. 9, aconnection12 including a disconnectablejoint assembly200 according to further embodiments of the present invention is shown therein. Thejoint assembly200 is covered by thecover assembly170. Thejoint assembly200 corresponds to and is constructed and can be installed in the same manner as thejoint assembly100 except that thecoupling bolt150 is replaced with a non-shear threaded coupling fastener orbolt250. Thecoupling bolt250 includes ahead256 having a tool receptor orsocket256A (e.g., a hex socket) defined therein to receive a driver. Thecoupling bolt250 may be, for example, a cap screw having a hex socket. In use, thecoupling bolt250 can be driven via thesocket256A to tighten thecoupling bolt250 to clamp the coupling lugs120,140, and can also be driven via thesocket256A to remove thebolt150. Other types and configurations of coupling fasteners may be used as well.

According to some embodiments, thecoupling bolt150 may be replaced with a shear bolt having a feature that remains (after the head has sheared off) to enable operative engagement with a driver to remove the bolt.

For example, with reference toFIG. 10, an alternative coupling threaded fastener orbolt350 is shown therein that can be used in place of thecoupling bolt150 in accordance with some embodiments of the invention. Thecoupling bolt350 is a shear bolt constructed and usable in the same manner as thecoupling bolt150 except that thelower head356 is configured or shaped to engage a driver. For example, as illustrated, thelower head356 can be a hex-shaped head configured to be received in a complementary hex-shaped socket of a driver. According to some embodiments, thelower head356 is sized (e.g., small enough in diameter) to provide clearance to permit the driver to fit down in thecounterbore144A (FIG. 4) about thelower head356. In use, thelower head356 can be used, after the neck354A andhead354 have been sheared off at a shear plane orsection354B, to drive (using the driver) thecoupling bolt350 out of the connector bore124 to disconnect theconnectors110,130.

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.

Claims (17)

That which is claimed is:

1. A disconnectable joint system for disconnectably electrically and mechanically connecting first and second electrical cables each including a respective electrical conductor, the disconnectable joint system comprising:

a first connector defining a first conductor bore and a first coupling portion, the first conductor bore configured to receive the conductor of the first cable, the first coupling portion including:

a first coupling bore defined therein; and

a first integral interlock feature;

a second connector defining a second conductor bore and a second coupling portion, the second conductor bore configured to receive the conductor of the second cable, the second coupling portion including:

a second coupling bore defined therein; and

a second integral interlock feature; and

a coupling fastener;

wherein:

the first and second coupling portions are mateable in an interlocked position wherein the first and second interlock features are interlocked with one another and the first and second coupling bores are substantially aligned;

when the first and second coupling portions are in the interlocked position, the coupling fastener can be inserted through the first and second coupling bores and tightened to securely couple the first and second connectors to one another;

the first and second connectors can be separated upon removal of the coupling fastener;

the first interlock feature includes an interlock slot; and

the second interlock feature includes an interlock post configured to be received in the interlock slot.

2. The disconnectable joint system ofclaim 1 wherein, when the first and second coupling portions are in the interlocked position, the first and second interlock features prevent relative axial displacement between the first and second coupling portions.

3. The disconnectable joint system ofclaim 1 wherein the coupling fastener is a shear bolt.

4. The disconnectable joint system ofclaim 3 wherein the shear bolt includes:

a first engagement feature to engage a first driver to enable the first driver to tighten the shear bolt onto the first and second connectors until the first engagement feature breaks off from a remaining portion of the shear bolt; and

a second engagement feature to engage the first or a second driver to enable the first or second driver to remove the shear bolt from the first and second connectors, wherein the second engagement feature is part of the remaining portion.

5. The disconnectable joint system ofclaim 1 wherein each of the first and second connectors includes a clamping shear bolt to secure the respective cable conductor therein.

6. The disconnectable joint system ofclaim 1 including an electrically insulating cover configured to surround the first and second connectors, the coupling fastener, and portions of the cables.

7. A disconnectable joint assembly for disconnectably electrically and mechanically connecting first and second electrical cables each including a respective electrical conductor, the disconnectable joint assembly comprising:

a first connector defining a first conductor bore and a first coupling portion, the first conductor bore configured to receive the conductor of the first cable, the first coupling portion including:

a first coupling bore defined therein; and

a first integral interlock feature;

a second connector defining a second conductor bore and a second coupling portion, the second conductor bore configured to receive the conductor of the second cable, the second coupling portion including:

a second coupling bore defined therein; and

a second integral interlock feature; and

a coupling fastener;

wherein:

the first and second coupling portions are mated in an interlocked position wherein the first and second interlock features are interlocked with one another and the first and second coupling bores are substantially aligned;

the coupling fastener extends through the first and second coupling bores and securely couples the first and second connectors to one another;

the first and second connectors can be separated upon removal of the coupling fastener;

the first interlock feature includes an interlock slot; and

the second interlock feature includes an interlock post received in the interlock slot.

8. The disconnectable joint assembly ofclaim 7 wherein the first and second interlock features prevent relative axial displacement between the first and second coupling portions.

9. The disconnectable joint assembly ofclaim 7 wherein the coupling fastener is a shear bolt.

10. The disconnectable joint assembly ofclaim 7 wherein each of the first and second connectors includes a clamping shear bolt to secure the respective cable conductor therein.

11. The disconnectable joint assembly ofclaim 7 including an electrically insulating cover surrounding the first and second connectors, the coupling fastener, and portions of the cables.

12. A method for disconnectably electrically and mechanically connecting first and second electrical cables each including a respective electrical conductor, the method comprising:

providing a disconnectable joint assembly including:

a first connector defining a first conductor bore and a first coupling portion, the first conductor bore configured to receive the conductor of the first cable, the first coupling portion including:

a first coupling bore defined therein; and

a first integral interlock feature;

a second connector defining a second conductor bore and a second coupling portion, the second conductor bore configured to receive the conductor of the second cable, the second coupling portion including:

a second coupling bore defined therein; and

a second integral interlock feature; and

a coupling fastener;

mating the first and second coupling portions in an interlocked position wherein the first and second interlock features are interlocked with one another and the first and second coupling bores are substantially aligned; and

with the first and second coupling portions in the interlocked position, inserting the coupling fastener through the first and second coupling bores and tightening the coupling fastener to securely couple the first and second connectors to one another;

the first interlock feature includes an interlock slot;

the second interlock feature includes an interlock post; and

mating the first and second coupling portions in the interlocked position includes inserting the interlock post in the interlock slot.

13. The method ofclaim 12 further including, after tightening the coupling fastener to securely couple the first and second connectors to one another:

removing the coupling fastener from the first and second connectors; and thereafter

separating the first and second connectors from one another to electrically disconnect the first and second cables.

14. The method ofclaim 12 wherein, when the first and second coupling portions are in the interlocked position, the first and second interlock features prevent relative axial displacement between the first and second coupling portions.

15. The method ofclaim 12 wherein the coupling fastener is a shear bolt, and the method includes tightening the shear bolt on the first and second coupling portions until a head shears off from the shear bolt.

16. The method ofclaim 12 wherein each of the first and second connectors includes a clamping shear bolt, and the method includes tightening each clamping shear bolt onto the associated conductor until a head shears off from the clamping shear bolt.

17. The method ofclaim 12 including surrounding the first and second connectors, the coupling fastener, and portions of the cables with an electrically insulating cover.

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